Ear protection device

ABSTRACT

An apparatus comprising a first curved band portion and a second curved band portion. The first curved band portion has a first end, a second end, an inner curved side and an outer curved side. The first curved band portion defines a passageway between the first end and the second end of the first curved band portion. The passageway has a first opening. The second curved band portion has a first end, a second end, an inner curved side and an outer curved side. A motion-restraint portion is proximate to the first end of the second curved band portion. The first end of the second curved band portion is insertable into the first opening of the passageway of the first curved band portion. The first curved band portion has a range of motion within the passageway of the second curved band portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is continuation of U.S. patent application Ser.No. 10/024,523, entitled “Ear Protection Device,” filed Dec. 21, 2001,now U.S. Pat. No. 6,499,146 the entire disclosure of which isincorporated herein, which claims priority to and is related to U.S.Provisional Application Ser. No. 60/259,114, filed Dec. 29, 2000,entitled “Ear Covering,” the entire disclosure of which is incorporatedherein by reference.

The present application is also related to U.S. applications Ser. Nos.09/521,241 and 09/978,591, both of which are entitled “Apparatus andMethod for Making an Ear Warmer Having Interior Seams,” the entiredisclosures of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

The invention in general relates to an ear protection device. Morespecifically, the invention relates to an ear protection device withadjustable bands.

Ear muffs that are worn over the top or around the back of a user's headare generally known. For example, U.S. Pat. No. 1,628,483 to Wieganddiscloses an ear protector. The ear protector includes a pair ofoval-shaped plates, each plate being formed with an inwardly extendingcontinuous flaring flange. The flange provides a conical profile. Theplates are connected together via slidably connected resilient arms. Theear protector includes a hold fast device or rivet for coupling each ofthe resilient arms to a respective oval plate. The resilient arms eachinclude a band for slidably receiving the other overlapping resilientarm. The bands hold the resilient arms together and allow for thesliding movement between the two resilient arms to allow the earprotector to be adjusted for a specific user. The ear protector can beworn with the resilient arms extending around the back of the head.

This known ear muff, however, does not effectively maintain its positionon a user's head. In addition, this ear muff does not allow a fabricmember to cover entirely the frame structure of the ear muff.

Thus, a need exists for frames for ear protection devices that maintaintheir position on a user's head. In addition, a need exists for a shell(e.g., made of fabric) that entirely covers the ear-protection-deviceframe.

SUMMARY OF THE INVENTION

An apparatus comprising a first curved band portion and a second curvedband portion. The first curved band portion has a first end, a secondend, an inner curved side and an outer curved side. The first curvedband portion defines a passageway between the first end and the secondend of the first curved band portion. The passageway has a firstopening. The second curved band portion has a first end, a second end,an inner curved side and an outer curved side. A motion-restraintportion is proximate to the first end of the second curved band portion.The first end of the second curved band portion is insertable into thefirst opening of the passageway of the first curved band portion. Thefirst curved band portion has a range of motion within the passageway ofthe second curved band portion.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of an ear protection device, accordingto an embodiment of the invention.

FIGS. 2A-2D show a perspective view, a side view, a top view and a frontview, respectively, of a first band portion, according to an embodimentof the invention.

FIGS. 3A-3E show a top perspective view, bottom perspective view, a sideview, a top view and a front view, respectively, of a second bandportion, according to an embodiment of the invention.

FIGS. 4A-4D show a perspective view, a side view, a rear view and afront view, respectively, of two band portions, according to anembodiment of the invention.

FIG. 5 shows a perspective view of an ear cup portion, according to anembodiment of the invention.

FIG. 6A shows a top view of shell membranes, according to an embodimentof the invention.

FIG. 6B shows a top view of the shell membranes shown in FIG. 6A whileassembled into a shell.

FIG. 7 shows a top view of shell membranes, according to anotherembodiment of the invention.

FIG. 8 shows a top view of an assembled shell, according to anotherembodiment of the invention.

FIG. 9 shows a top view of shell membranes, according to anotherembodiment of the invention.

FIG. 10 shows a top view of shell membranes of FIG. 9 partially sewnduring an immediate step of assembling an ear protection device.

FIG. 11 shows a top view of shell membranes, according to anotherembodiment of the invention.

FIG. 12 shows a top view of the assembled shell based on the shellmembranes shown in FIG. 1.

FIG. 13 shows a top view of shell membranes, according anotherembodiment of the invention.

FIG. 14 shows a top view of an assembled shell based on the shellmembranes shown in FIG. 13.

FIG. 15 shows a top view of shell membranes, according to anotherembodiment of the invention.

FIG. 16 shows a top view of an assembled shell based on the shellmembranes shown in FIG. 15.

FIG. 17 shows a perspective view of two band portions, according to anembodiment of the invention.

FIG. 18 shows an assembly view of a frame, according another embodimentof the invention.

FIG. 19 shows an assembly view of an ear protection device, according toanother embodiment of the invention.

FIG. 20 shows an assembly view of an ear protection device, according toanother embodiment of the invention.

FIG. 21 shows an assembly view of an ear protection device, according toanother embodiment of the invention.

FIG. 22 shows an assembly view of an ear protection device, according toanother embodiment of the invention.

DETAILED DESCRIPTION

FIG. 1 shows a perspective view of an ear protection device, accordingto an embodiment of the invention. As shown in FIG. 1, the earprotection device 10 includes a head band portion 12 having an innerside 14 and an outer side 16. Ear protection device 10 also includes afirst end portion 18 and a second end portion 20. The first end portion18 and second end portion 20 are connected to respective ear portions22. Each ear portion 22 has an inner side 24 and an outer side 26. Theear protection device 10 is covered in a textile material, such asfleece. Note that the head band portion 12 is covered by excess materialthat gathers.

FIGS. 2A-2D show a perspective view, a side view, a top view and a frontview, respectively, of a first band portion, according to an embodimentof the invention. Band portion 200 includes a first end 34, a second end36, an inner side 35 and an outer side 37. Band portion 200 includes araised mounting surface 38 disposed at the outer side 37 and proximateto the first end 34. Band portion 200 also includes a motion-restraintportion 40 disposed at the outer side 37 and proximate to the second end36 of band portion 200. Although the mounting surface 38 andmotion-restraint portion 40 are shown as being integrally formed withthe band portion 200, they can be formed separately and attached to theband portion 200. In an alternative embodiment, the motion-restraintportion can be a detent that is integrally formed with the band portionalong only a single side of the detent while the remaining sides of thedetent are separated (or cut out) from the band portion.

FIGS. 3A-3E show a top perspective view, bottom perspective view, a sideview, a top view and a front view, respectively, of a second bandportion, according to an embodiment of the invention. Band portion 210includes a first end 42, a second end 44, an inner side 45 and an outerside 47. Band portion 210 includes a raised mounting surface 46 disposedat the outer side 47 and proximate to the second end 44. Band portion210 further includes a base member 211, side members 212 and uppermembers (or flanges) 50. The side members 212 are connected along bothsides of the base member 211. The upper members 50 are connected to theside members 212 and protrude over base member 211.

The base member 211, side members 212 and upper members 50 define apassageway 215 along the band portion 210, lengthwise. In other words,the base member 211, side members 212 and upper members 50 bound achannel on various sides into which the band portion 200 can beslideably engaged. Thus, as the band portion 200 is moved through thepassageway 215, the movement of band portion 200 is limited by the basemember 211, side members 212 and upper members 50. The passageway 215includes an opening 216 into which the band portion 200 can be initiallyinserted.

FIGS. 4A-4D show a perspective view, a side view, a rear view and afront view, respectively, of two band portions, according to anembodiment of the invention. As shown in FIGS. 4A-4D, band portion 200is inserted into the passageway of band portion 210 through opening 216to provide a band that has an adjustable length. More specifically, themotion-restraint portion 40 of band portion 200 is engagable with theopening 216 of passageway 215 of band portion 210. Once band portion 200has been inserted through opening 216, the motion-restraint portion 40engages the portions of band portion 210 that defines opening 216. Thisallows motion-restraint portion 40 to prevent band portion 200 fromexisting passageway 215 of band portion 210. Consequently, the bandportion 200 has a range of motion within the passageway 215 of bandportion 210 once the band portion 200 has been inserted into passageway215 of band portion 210. This range of motion within the passageway 215is limited on the end with the opening 216 by the engagement ofmotion-restraint portion 40 of band portion 210.

In an alternative embodiment, the motion-restrain portion can removablyengage the passageway of the other embodiment. For example, themotion-restraint portion can be a detent integrally formed with the bandportion along only a single side of the detent while the remaining sidesof the detent are separated (or cut out) from the band portion. Thisallows the band portion to be removably inserted into the passageway ofthe other band portion. In other words, the detent can be depressed todisengage from the opening the passageway thereby allowing the one bandportion to be removed from the other band portion.

In another alternative embodiment, the motion-restraint portion of oneband portion can at least partially engage other openings within thepassageway of the other band portion. For example, the motion-restraintportion can be a detent and the upper members of the band portion thatdefines the passageway can extend so that they overlap slightly with thedetent. This allows the detent to engage partially the openings definedby the upper members thereby causing a slight hesitation due to frictionwhen the band portions are moved within the range of motion. Once thispartial engagement is overcome, the band portions can move within therange of motion.

In yet another alternative embodiment, the upper members that define thepassageway of one band portion can further extend so that the detent ofthe other band portion removably engages the openings defined by theupper members. In such an embodiment, the two band portions will have arange of motion that includes one or more positions where the detentremovably engages the openings in the passageway. This removableengagement allows the position of the band portion to be temporarilylocked within the passageway of the other band portion.

In yet another alternative embodiment, detent-engageable openings of thepassageway of one band portion and the detent of the other band portioncan be located on any of their respective sides. For example, the detentcan be located on either side or both sides of the band portion wherethe detent-engagable openings of the passageway are disposed atcorresponding locations on the other band portion (i.e., on the matchingside or on both sides of the passageway). Alternatively, the detent canbe located on the inner side the band portion where the detent-engagableopenings of the passageway are disposed at corresponding location(s) onthe inner side of the other band portion. In yet another embodiment,multiple detents can be located at different locations (i.e., one detenton the outer side and another detent on the inner side) of the bandportion where the detent-engagable openings of the passageway aredisposed at a corresponding locations on the other band portion.

Although motion-restraint portion 40 of band portion 200 is shown inFIGS. 2A-2D as a detent, other configurations are possible. For example,the motion-restraint portion can be a rivet that is coupled to the bandportion once the band portion is inserted into the passageway of theother band portion. Such a rivet can be, for example, fixedly attachedor removably attached to the band portion once the band portion isinserted into the passageway of the other band portion.

FIG. 5 shows a perspective view of an ear cup portion, according to anembodiment of the invention. As shown in FIG. 5, ear cup portion 54includes a conical portion 56 having a transition portion 58 extendingfrom the side of the conical portion 56. The transition portion 56 isintegrally formed with mount portion 60, which includes a hole 62.

Two ear cup portions 54 can each be attached to an end of the bandportions 200 and 210. In other words, one ear cup portion 54 can beattached to the raised mounting surface 38 of band portion 200 andanother ear cup portion 54 can be attached to the raised mountingsurface 46 of band portion 210. Ear cup portions 54 can be attached toband portions 200 and 210 by a fastener, such as for example, rivet 64.In an alternative embodiment, either the ear cup portion or the raisedmounted surface of the band portions can include an integrally formedrivet for snap-action engagement with a hole in the corresponding matingstructure. Note that band portions 200 and/or 210, and/or ear cupportions 54 collectively are sometimes referred to herein as a “frame”.

FIG. 6A shows a top view of shell membranes, according to an embodimentof the invention. The shell membranes include outer membrane 310, innermembrane 320, and ear membranes 330 and 340. FIG. 6B shows a top view ofthe shell membranes shown in FIG. 6A while assembled into a shell. Asshown in FIG. 6B, the membranes 310, 320, 330 and 340 can be arrangedtogether and then sown with a seam along the perimeter. The assembledshell 300 includes two openings 350 and 360 into which portions of theframe can be inserted. For example, the band portion 200 with theattached ear cup portion 54 and be inserted into opening 350, and theband portion 210 with the attached ear cup portion 54 can be insertedinto opening 360. Additional details and variations of the shellmembranes are described in U.S. Pat. No. 5,835,609 to Le Gette et al.entitled “Ear Protection Device;” the disclosure of which isincorporated herein by reference.

After being inserted into shell 300, the band portions 200 and 210 canhave an adjustable length to accommodate the use of the ear protectiondevice 10 by users having different size heads or by the same user whileextending over the top or around the band of that user's head. In otherwords, once the band portions 200 and 210 are inserted into andassembled within the shell 300, the length of the band portions 200 and210 can be adjusted by moving band portion 200 within the passageway 215of band portion 210.

In some embodiments, the band portions can be separated from each otherwhile disposed within shell 300. For example, where the motion-restraintportion of one band portion is a disengageable detent, the detent can bedisengaged from an opening of the passageway of the other band portion,and the band portion can be removed from the passageway of the otherband portion. Then, the band portion with the attached ear cup portion54 can be removed from shell 300 through opening 350, and the other bandportion with the attached ear cup portion 54 can be removed from shell300 through opening 360.

This allows the ear protection device 10 to have interchangeable shells.In other words, different shells can be used to cover the same framebecause the band portions can be separated from each other whiledisposed within one shell and reassembled in another shell. Suchinterchangeable shells, for example, can have different colors or logosfor use with a single frame.

FIG. 7 shows a top view of shell membranes, according to anotherembodiment of the invention. As shown in FIG. 7, the shell 400 includesouter membrane 410 and inner membrane 420. To assemble an ear protectiondevice using shell 400, the outer membrane 410 and inner membrane 420can be positioned over the other, with the components of the framedisposed between the two membranes 410 and 420, and then the membranes410 and 420 can be sewn along their perimeter.

FIG. 8 shows a top view of an assembled shell, according to anotherembodiment of the invention. As shown in FIG. 8, the shell 500 has aninner membrane 510, outer membrane 520 and elastic membranes 530 and 540(shown in phantom). The membranes 510, 520, 530 and 540 are sewn alongthe perimeter. The elastic membranes 530 and 540 can be disposed betweenthe inner membrane 510 and the outer membrane 520. The elastic membranes530 and 540 can form “gathers” in the central portion of the shell 500.The elastic membranes 530 and 540 can gather any additional material ofmembranes 510 and 520 when the ear protection device is in aconfiguration other than open. In other words, membranes 510 and 520 canbe fully stretched when the ear protection device is in an openconfiguration and less than fully stretched when the ear protectiondevice is in a closed configuration. Thus, when in the closedconfiguration, the elastic membranes 530 and 540 can gather membranes510 and 520.

FIG. 9 shows a top view of shell membranes, according to anotherembodiment of the invention. As shown FIG. 9, the shell 600 includesouter 610 membrane and inner membrane 620. Outer membrane 610 includesend portions 611 and 612. Inner membrane 620 includes end portions 621and 622. The end portions 611, 612, 621 and 622 can include, forexample, an elastic material and can be folded over the related frameportion when assembled. The doubled-over arrangement of the end portions611, 612, 621 and 622 can provide cushioning for the frame against thewearer's head. The elastic material can affect the appearance of the earprotection device by pulling the outer membrane 610 and inner membrane620 tight around the perimeter of the ear cup portions of the frame. Inother words, the elastic material can be pulled over the related frameportions so that the outer membrane 610 and inner membrane 620 areremoveably secured to the related frame portions without being sewnalong a seam.

FIG. 10 shows a top view of shell membranes of FIG. 9 partially sewnduring an immediate step of assembling an ear protection device. Asshown in FIG. 10, the ear protection device can be assembled byinitially sewing a portion of the perimeter 630 and leaving a portion ofthe perimeter 640 and 650 not sewn. Two ear cup portions of the frameeach can be connected to a respective band portion. Each band portionwith its attached ear cup portion of the frame can then be positionedwithin the shell by insertion through the portions 640 and 650. Theinner band portion can then be removably inserted into the passageway ofthe outer band (as described above, for example, in reference to FIGS.4A-4D). In an alternative embodiment, the shell 600 can be turned insideout after the portions of perimeter 630 have been sewn.

FIG. 11 shows a top view of shell membranes, according to anotherembodiment of the invention. The shell 700 includes outer membrane 710and ear membranes 720 and 730. Outer membrane 710 includes middleportion 715, which is integrally formed with the remaining portions ofouter membrane 710. Ear membranes 720 and 730 each have their ownelastic membrane attached to a portion of the perimeter of therespective ear membrane. In addition, the outer membrane 710 can haveits own elastic membrane attached to the perimeter of the ear portionsof outer membrane 710. Note that although elastic membranes are shown onboth the outer membrane 710 and ear membranes 720 and 730, alternativeembodiments are possible where the elastic membrane is disposed at onlythe outer membrane or only the ear membranes.

Shell 700 can be assembled by attaching the edge portions 721 and 731 ofear membranes 720 and 730, respectively, to portions 711 and 712 ofouter membrane 710. The middle portion 715 of outer membrane 710 can befolded over and attached to the portion 716 of the outer membrane 710.This is shown in FIG. 12, which shows a top view of the assembled shellbased on the shell membranes shown in FIG. 11. The ear membranes 720 and730 optionally can be turned inside out with regards to thecorresponding portions of outer membrane 710. Consequently, theattachment (e.g., a sewn seam) is disposed in the interior formed byouter membrane 710 and ear membranes 720 and 730. The frame can then beinserted into the interior formed by outer membrane 710 and earmembranes 720 and 730. The elastic membranes attached to outer membrane710 and ear membranes 720 and 730 tend to draw the perimeter of theouter membrane 710 and ear membranes 720 and 730 inwardly. Thus, thecorresponding portions of shell 700 close in around the ear cup portionsof the frame. Although not shown explicitly in FIG. 12, the earprotection device will have a curvature corresponding to the shape ofthe frame.

In an alternative embodiment, the ear membranes need not be attached toportions of the outer membrane. Rather, the middle portion of the outermembrane can be folded over and attached. Then, the frame can beinserted into the interior formed by the outer membrane and the middleportion of the outer membrane. Finally, the ear membranes can bedisposed and maintained over the ear cup portions of the frame by theelastic membranes attached to the ear membranes and the outer membrane.

FIG. 13 shows a top view of shell membranes, according to anotherembodiment of the invention. As shown in FIG. 13, shell 800 includes anouter membrane 810 and an inner membrane 820. The lengths of bandportions 811 and 821 of outer membrane 810 and inner membrane 820,respectively, are greater than the corresponding portion of the frame.This extra length allows the shell 800 to gather with extra materialabout the portions 811 and 821.

In addition, the ear portions 822 and 823 of inner membrane 820 can havelengths along direction 824 greater than the corresponding ear cupportions of the frame. An elastic membrane, while stretched, can beattached to the perimeter of ear portions 822 and 823. This extra sizeof ear portions 822 and 823 along direction 824 and the stretchedelastic membrane allows the ear portions 822 and 823 to draw inwardly.

FIG. 14 shows a top view of an assembled shell based on the shellmembranes shown in FIG. 13. As shown in FIG. 14, the outer membrane 810and inner membrane 820 can be attached together at the positions 830 and831. The frame can be inserted into an interior defined between theouter membrane 810 and inner membrane 820. The inward draw of theelastic membrane of ear portions 822 and 823 allows these to gatherabout the ear cup portions of the frame when inserted into an interiorformed by inner membrane 810 and outer membrane 820.

FIG. 15 shows a top view of shell membranes, according to anotherembodiment of the invention. As shown in FIG. 15, shell 900 includes earmembranes 910, 920, 930 and 940, and middle membrane 950. The middlemembrane 950 can be a knit tube or a membrane folded over to form a tubeshape. Ear membranes 910 and 930 can be attached together, and earmembranes 920 and 940 can be attached together. Once attached, forexample, by sewing, these attached ear membranes can be attached tomiddle membrane 950. Alternatively, these attached ear membranes can beturned inside out and then attached to middle membrane 950. In yetanother alternative, the attached ear membranes can include additionelastic membranes as discussed above in reference to, for example, FIG.11. FIG. 16 shows a top view of an assembled shell based on the shellmembranes shown in FIG. 15.

FIG. 17 shows a perspective view of two band portions, according to anembodiment of the invention. As shown in FIG. 17, band portion 1000includes a first end 1001, a second end 1002, an inner side 1003 and anouter side 1004. The first end 1001 of band portion 1000 includes anopening. The second end 1002 of band portion 1000 includes a mountingportion 1005. Band portion 1000 has a base member 1006, side members1007 and upper member 1008. Base member 1006, side members 1007 andupper members 1008 define a passageway along the band portion 1000,lengthwise. The passageway includes openings along the base member 1006,side members 1007 and upper member 1008.

Band portion 1010 includes a first end 1011 and a second end 1012. Bandportion 1010 also includes a motion-restraint portion 1013 (shown as adetent in phantom) on the outer side of the first end 1011 of bandportion 1010. Band portion 1010 also includes a mounting portion 1015 onthe second end 1012.

Band portion 1010 can be slidably engaged into the passageway of bandportion 1000. The motion-restraint portion 1013 of band portion 1010 canbe engaged through opening 1009 of the passageway. Note that the bandportion 1000 can easily flex either inwardly or outwardly because boththe base member 1006 and the upper member 1008 have openings. In otherwords, as the band portions 1000 and 1010 are adjusted (e.g., while bandportion 1010 is slidably engaged within the passsageway of band portion1000), these band portions can easily flex inwardly or outwardly due tothe openings in the base member 1006 and the upper member 1008 of bandportion 1000. In an alternative embodiment, the motion-restraint portioncan be integrally formed with the band portion along only a single sideof the detent while the remaining sides of the detent are separated (orcut out) from the band portion. Such an embodiment allows the one bandportion to be removably and slideably engaged into the passageway of theother band portion.

In another alternative embodiment, the motion-restraint portion can be adisengageable detent. The detent can be removably engageable with any ofthe openings of the passageway of the other band portion. Thus, thedetent can be removably engageable into the openings of the upper memberof the other band portion. This allows the band portions to betemporarily locked in multiple possible positions within the range ofmotion for the one band portion within the passageway of the other bandportion. Note also that although the detent can be on the outer side ofthe band portion thereby corresponding to detent-engageable openings onthe upper member of the other band portion, other arrangements arepossible. For example, a detent can be located on any of the four sidesof the band portion (either alone or in combination with detents onother sides) because the band portion includes openings on its foursides: the base member, the side members and the upper member.

FIG. 18 shows an assembly view of a frame, according another embodimentof the invention. As shown FIG. 18, the frame 1100 includes a band 1110and ear cup portion 1120. Note that although a single ear cup portion1120 is shown in FIG. 18, the frame 1100 includes a second ear cupportion that is attached to the band 1110 on the side opposite from earcup portion 1120.

Ear cup portion 1120 includes attachment portions 1121 and 1122, ear cup1124 and cushion insert 1126. Cushion insert 1126 can be made of, forexample, urethane foam. The cushion insert 1126 can be attached to earcup 1124 by, for example, glue. Cushion insert 1126 can providecushioning between the ear cup 1124 and the user's head.

Attachment portions 1121 and 1122 of ear cup portion 1120 are proximaland distal, respectively, to the band 1110. The end of the band 1110 canbe inserted into the attachment portions 1121 and 1122 so that band 1110is attached to ear cup portion 1120 by, for example, a friction fit.Such a friction fit allows the band 1110 to be removed from andreattached to ear cup portion.

FIG. 19 shows an assembly view of an ear protection device, according toanother embodiment of the invention. As shown in FIG. 19, ear protectiondevice 1200 includes a band 1210, a band membrane 1220, ear cup portions1230 and 1240 and ear cup membranes 1250 and 1260. The band membrane1220 can be, for example, elastic piping with binding on the upper andlower side of the piping that allows the band membrane 1220 to fit overthe band 1210. The band 1210 can be, for example, an adjustablespring-like band having two portions. Each end of the band 1210 can havea protrusion-locking portion 1211 and 1212. More specifically,protrusion-locking portions 1211 and 1212 can have a barbed shape.

Ear cup portions 1230 and 1240 can be made of, for example, a semi-rigidmaterial such as foam. Protrusion-locking portions 1211 and 1212 can beinserted into ear cup portions 1230 and 1240, respectively. Note thatprotrusion-locking portion 1211 is shown in phantom within ear cupportion 1230 for illustrative purposes. The barbed shape ofprotrusion-locking portions 1211 and 1212 allows the protrusion-lockingportions 1211 and 1212 to be retained within the ear cup portions 1230and 1240. In one embodiment, protrusion-locking portions 1211 and 1212can be inserted into ear cup portions 1230 and 1240, respectively, withglue to provide additional retention.

The ear cup membranes 1250 and 1260 each can be made of, for example, afabric material on both sides thereby forming an interior into which earcup portions 1230 and 1240, respectively, can be inserted. In otherwords, ear cup membranes 1250 and 1260 can be covers into which ear cupportions 1230 and 1240, respectively, can be inserted.

FIG. 20 shows an assembly view of an ear protection device, according toanother embodiment of the invention. As shown in FIG. 20, ear protectiondevice 1300 includes a band 1310, a band membrane 1320, ear cup portions1330 and 1340 and ear cup membranes 1350 and 1360. The band membrane1320 can be, for example, elastic piping with a binding on the upper andlower side of the piping that allows the band membrane 1320 to fit overthe band 1310. The band 1310 can be, for example, an adjustablespring-like band having two portions. Each end of the band 1310 can becoupled to a protrusion-locking portion 1311 and 1312. Morespecifically, protrusion-locking portions 1311 and 1312 can have a ballconnector configured to lock into a ball-joint connection with the earcup portions 1330 and 1340. The protrusion-locking portions 1311 and1312 can have a post configuration that can friction fit into the clipends of the band 1310. Such a post-clip configuration allows the ear cupportions 1330 and 1340 to rotate about the ends of band 1310 when in aclosed configuration.

Ear cup portions 1330 and 1340 can be made of, for example, moldedplastic. Ear cup portions 1330 and 1340 each can include a joint portionof a ball-joint connection that is configured to connect withprotrusion-locking portions 1311 and 1312. The joint portion of each earcup portions 1330 and 1340 can be disposed at an end proximal toprotrusion-locking portions 1311 and 1312. Thus, protrusion-lockingportions 1311 and 1312 can be removably connected to ear cup portions1330 and 1340, respectively.

The ear cup membranes 1350 and 1360 each can be made of, for example, afabric material on both sides thereby forming an interior into which earcup portions 1330 and 1340, respectively, can be inserted. In otherwords, ear cup membranes 1350 and 1360 can be covers into which ear cupportions 1330 and 1340, respectively, can be inserted.

FIG. 21 shows an assembly view of an ear protection device, according toanother embodiment of the invention. As shown in FIG. 21, ear protectiondevice 1400 includes a band 1410, a band membrane 1420, ear cup portions1430 and 1440 and ear cup membrane 1450. The band membrane 1420 can be,for example, elastic piping with a binding on the upper and lower sideof the piping that allows the band membrane 1420 to fit over the band1410. The band 1410 can be, for example, an adjustable spring-like bandhaving two portions. Each end of the band 1410 can be coupled to aprotrusion-locking portion 1411 and 1412. More specifically,protrusion-locking portions 1411 and 1412 each can have a clampconnector configured to lock by a friction fit into a post within theear cup portions 1430 and 1440. Such a hinge-post configuration allowsthe ear cup portions 1430 and 1440 to rotate about the ends of band 1410when in a closed configuration.

Ear cup portions 1430 and 1440 can be made of, for example, moldedplastic. Protrusion-locking portions 1411 and 1412 can be removablyconnected to ear cup portions 1430 and 1440, respectively.

The ear cup membrane 1450 can be made of, for example, a fabric materialon both sides thereby forming an interior into which ear cup portion1430 can be inserted. In other words, ear cup membrane 1450 can be acover into which ear cup portion 1430 can be inserted. Note thatalthough not shown in FIG. 21, an additional ear cup membrane can beused to cover ear cup portion 1440.

FIG. 22 shows an assembly view of an ear protection device, according toanother embodiment of the invention. As shown in FIG. 22, ear protectiondevice 1500 includes a band 1510, a band membrane 1520, ear cup portions1530 and 1540 and ear cup membranes 1550 and 1560. The band membrane1520 can be, for example, a cloth tube into which band 1510 can beinserted. The band membrane 1520 can include ends 1521 and 1522 that canbe made of, for example, lycra or similar elastic material. The band1510 can be, for example, an adjustable spring-like band having twoportions. One end of the band 1510 includes a protrusion-locking portion1511 and the other end of band 1510 includes a protrusion-lockingportion 1512. More specifically, protrusion-locking portions 1511 and1512 each can have a knob configured to lock by a snap fit into a holein the ear cup portions 1530 and 1540. Such a snap-fit configurationallows the ear cup portions 1530 and 1540 to rotate about the ends ofband 1510 when in a closed configuration.

Ear cup portions 1530 and 1540 can be made of, for example, moldedplastic. The ear cup membranes 1550 and 1560 each can be made of, forexample, a fabric material on both sides thereby forming an interiorinto which ear cup portions 1530 and 1540 can be inserted. In otherwords, ear cup membranes 1550 and 1560 can be a cover into which ear cupportions 1530 and 1540 can be inserted.

While various embodiments of the invention have been described above, itshould be understood that they have been presented by way of exampleonly, and not limitation. Thus, the breadth and scope of the presentinvention should not be limited by any of the above-describedembodiments, but should be defined only in accordance with the followingclaims and their equivalents.

The previous description of the embodiments is provided to enable anyperson skilled in the art to make or use the invention. While theinvention has been particularly shown and described with reference toembodiments thereof, it will be understood by those skilled in the artthat various changes in form and details may be made therein withoutdeparting from the spirit and scope of the invention.

For example, although certain frame embodiments are described as beinginserted into certain shell embodiments, other arrangements arepossible. Any of the frame embodiments described above can be insertedinto other shell configurations disclosed in, for example, U.S. Pat. No.5,835,609, and pending U.S. applications Ser. Nos. 09/521,241 and09/978,591, both of which are entitled “Apparatus and Method for Makingan Ear Warmer Having Interior Seams.” In addition, any of the shellembodiments described above can be used in combination with the framesdescribed in U.S. Pat. No. 5,835,609. The entire disclosures of U.S.Pat. No. 5,835,609 and pending U.S. applications Ser. Nos. 09/521,241and 09/978,591, are incorporated herein by reference.

1. An ear protection device comprising: a band, said band including afirst end, a second end, a first locking protrusion located proximate tosaid first end, and a second locking protrusion located proximate tosaid second end, the band and the first locking protrusion beingunitarily formed; a band membrane, said band membrane covering a portionof said band; a first ear cup portion, said first ear cup portion beingconfigured to receive said first locking protrusion to fixedly couplethe first ear cup portion to the band; and a second ear cup portion,said second ear cup portion being configured to receive said secondlocking protrusion, each of said first locking protrusion and saidsecond locking protrusion including a barbed shape.
 2. The earprotection device of claim 1, wherein said first locking protrusion isconfigured to be inserted into and retained within said first ear cupportion.
 3. The ear protection device of claim 1, wherein said first earcup portion is formed of a semi-rigid material, said first lockingprotrusion being configured to be inserted into and retained within saidfirst ear cup portion.
 4. The ear protection device of claim 3, whereinsaid semi-rigid material is foam.
 5. The ear protection device of claim1, further comprising: a first ear cup membrane, said first ear cupmembrane defining an interior configured to receive said first ear cupportion; and a second ear cup membrane, said second ear cup membranedefining its own interior configured to receive said second ear cupportion.
 6. An ear protection device, comprising: a band having a firstband member and a second band member, the first band member beingslideably coupled to the second band member, the first band memberincluding a first end portion and a second end portion opposite thefirst end portion, a locking protrusion located proximate to the firstend portion of the first band member, the first band member and thelocking protrusion being unitarily formed; and an ear cup portion, theear cup portion being configured to receive the locking protrusion, thelocking protrusion including a barbed shape.
 7. The ear protectiondevice of claim 6, further comprising: a band membrane configured tocover at least a portion of the band.
 8. The ear protection device ofclaim 6, wherein the locking protrusion is configured to be insertedinto and fixedly retained within the ear cup portion.
 9. The earprotection device of claim 6, wherein the ear cup portion is formed of asemi-rigid material, the locking protrusion is configured to be insertedinto and fixedly retained within the ear cup portion.
 10. The earprotection device of claim 9, wherein the semi-rigid material is foam.11. An ear protection device, comprising: a band, the band including afirst end, a second end, a first locking protrusion located proximate tothe first end of the band, a second locking protrusion located proximateto the second end of the band, the first locking protrusion and thesecond locking protrusion extending from the band in substantially thesame direction; a first ear cup portion, the first ear cup portion beingconfigured to receive the first locking protrusion to fixedly couple thefirst ear cup portion to the band, the first locking protrusionincluding a barbed shape; and a second ear cup portion, the second earcup portion being configured to receive the second locking protrusion.12. The ear protection device of claim 11, further comprising: a bandmembrane configured to cover at least a portion of the band.
 13. The earprotection device of claim 11, wherein the first locking protrusion isconfigured to be inserted into and retained within the first ear cupportion.
 14. The ear protection device of claim 11, wherein the firstear cup portion is formed of a semi-rigid material, the first lockingprotrusion is configured to be inserted into and retained within thefirst ear cup portion.
 15. The ear protection device of claim 14,wherein the semi-rigid material is foam.
 16. The ear protection deviceof claim 11, wherein the band has a first band member and a second bandmember, the first band member is slideably coupled to the second bandmember.
 17. The ear protection device of claim 11, wherein the band andthe first locking protrusion are unitarily formed.